Fillet molding mold and bonding method

Abstract

To provide technology for molding fillets with reduced variations.SOLUTION: A fillet molding mold has a fillet molding surface that is placed in contact with a first member, and the fillet molding surface has a curved surface that molds a fillet of an adhesive at a corner formed by the first member and a second member that is bonded to the first member by an adhesive.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to fillet forming dies and bonding methods. [Background technology]

[0002] Conventionally, attempts have been made to control the fillet shape when two components are bonded together using an adhesive made of a resin material. For example, in Patent Document 1, a through hole with a buffer function is used to adjust the amount of resin material supplied to seal the gap between the two components, thereby controlling the fillet shape. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2000-260791 Summary of the Invention [Problem to be solved by the invention]

[0004] However, even when the amount of resin material supplied to the gap is adjusted, variations in the shape of the fillet may occur depending on the properties of the resin material, such as its viscosity. [Means for solving the problem]

[0005] The present disclosure can be realized in the following forms.

[0006] (1) According to a first aspect of the present disclosure, there is provided a fillet forming die. The fillet forming die includes a fillet forming surface disposed in contact with a first member, the fillet forming surface having a curved surface that forms a fillet of the adhesive at a corner formed by the first member and a second member bonded to the first member with an adhesive. According to this aspect, by disposing the fillet forming die with the fillet forming surface in contact with the first member, it is possible to suppress misalignment of the fillet forming die with respect to the first member and reduce variation in the shape of the fillet formed in the adhesive. Therefore, it is possible to suppress stress concentration at the bonded portion between the first member and the second member and improve the bond strength between the first member and the second member. (2) The fillet forming die of the above embodiment may have an opposing surface connected to the fillet forming surface and abutting against the second member, the fillet forming die having a shape extending in the direction of the corner, and the shape of the fillet forming surface in a side view of the fillet forming die along the direction of the corner may be an arc. According to this embodiment, by abutting the opposing surface against the second member, misalignment between the fillet forming die and the second member can be suppressed, further reducing variation in the shape of the fillet formed in the adhesive. Furthermore, when the adhesive portion between the first member and the second member extends linearly, a fillet can be efficiently formed in this adhesive portion. Furthermore, since the cross-sectional shape of the fillet can be an arc, adhesive strength can be further improved. (3) In the fillet forming die of the above embodiment, the opposing surface may have a first side connected to the fillet forming surface, a second side opposite to the first side, and a groove extending from the first side to the second side. According to this embodiment, excess adhesive is guided along the groove to the second side, thereby preventing excess adhesive from adhering to the first member or the second member. (4) A second aspect of the present disclosure provides a bonding method for bonding a first member and a second member using a fillet forming die. The fillet forming die includes a fillet forming surface and an opposing surface connected to the fillet forming surface. The bonding method includes a first step of applying an adhesive to the first member; a second step of placing the fillet forming die and the second member relative to the first member on which the adhesive is applied so that the fillet forming surface abuts against the first member and the opposing surface abuts against the second member; and a third step of separating the fillet forming die from the first member and the second member after the adhesive has hardened and bonded the first member and the second member. This aspect reduces variation in the shape of the fillet formed in the adhesive. Therefore, stress concentration at the bonding portion between the first member and the second member can be suppressed, improving the bonding strength between the first member and the second member. (5) In the bonding method of the above aspect, in the second step, after temporarily fixing the fillet forming mold so that the fillet forming surface abuts against the first member, the second member may be brought closer to the first member on which the adhesive is applied until the second member abuts against the opposing surface. According to this aspect, by temporarily fixing the fillet forming mold, it is possible to improve the positional accuracy of the second member relative to the first member. The present disclosure can be realized in various forms other than those described above, for example, in the form of a method for manufacturing a fillet-formed product. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. [Figure 2] 10A to 10C are cross-sectional views illustrating a bonding step. [Figure 3] 10A to 10C are diagrams illustrating a bonding step according to the second embodiment. [Figure 4] FIG. 10 is a view illustrating a fillet forming die according to a third embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0008] A. First embodiment: A1. Fillet forming mold: FIG. 1 is a perspective view of a fillet forming die 10. FIG. 2 is a cross-sectional view illustrating a bonding process for bonding a first member ME1 and a second member ME2. As shown by "S16" in FIG. 2, the fillet forming die 10 is used to form a fillet FI in an adhesive GL for bonding the first member ME1 and the second member ME2. In this disclosure, a fillet FI refers to the shape of the end of the adhesive GL, which has a curved surface. FIG. 1 shows arrows indicating mutually orthogonal X, Y, and Z directions. The Z direction is a vertically upward direction. The arrows indicating the X, Y, and Z directions are also appropriately illustrated in other figures so that the illustrated directions correspond to those in FIG. 1. In the following description, when specifying the direction, the direction indicated by the arrow in each figure is indicated by "+" and the opposite direction is indicated by "-", and positive and negative signs are used in combination to indicate the direction. Hereinafter, the +Z direction is also referred to as "up" and the -Z direction is also referred to as "down."

[0009] As shown in FIG. 1 , the fillet forming die 10 includes a fillet forming surface 11 and an opposing surface 12 connected to the fillet forming surface 11. The fillet forming die 10 of this embodiment has a cylindrical shape extending in the axial direction. The fillet forming surface 11 is a surface that is arranged to abut against the first member ME1 in a bonding process described later. The opposing surface 12 is a surface that is arranged to abut against the second member ME2 in a bonding process described later. The fillet forming surface 11 has a curved surface that forms a fillet FI of adhesive GL at the corner formed by the first member ME1 and the second member ME2. In this embodiment, the entire fillet forming surface 11 is a curved surface that forms a fillet FI of adhesive GL at the corner formed by the first member ME1 and the second member ME2. In this embodiment, the opposing surface 12 is a substantially flat surface.

[0010] The opposing surface 12 has a first side SI1 connected to the fillet forming surface 11 and a second side SI2 opposite to the first side SI1. In FIG. 1, the first side SI1 is indicated by a dashed line. As shown by "S10" in FIG. 2, the shape of the fillet forming surface 11 in a side view of the fillet forming die 10 as seen along the axial direction is an arc. It is generally known that an arc-shaped cross-sectional shape of the fillet FI improves adhesive strength. Therefore, by having an arc-shaped shape in a side view of the fillet forming surface 11, it is possible to improve adhesive strength between the first member ME1 and the second member ME2.

[0011] In the bonding step described below, after the adhesive GL has hardened, the fillet forming mold 10 is separated from the hardened adhesive GL. Therefore, it is preferable that the fillet forming mold 10 is made of a material that can be easily removed from the hardened adhesive GL. Specifically, a form in which a mold release agent is applied to the surface of a metal fillet forming mold 10 such as iron, or a form in which a layer of a fluororesin such as polytetrafluoroethylene is formed on the surface of a metal fillet forming mold 10 can be used.

[0012] A2.Gluing process: Using Figure 2, a bonding step for realizing a bonding method will be described by exemplifying a case in which two fillet forming dies 10 are used to bond a first member ME1 and a second member ME2 having the shapes shown in Figure 2. Figure 2 shows a cross section taken along a plane perpendicular to the axial direction of the fillet forming die 10. As shown in Figure 1, the first member ME1 is an L-shaped member with a bent tip of a flat plate. The second member ME2 is a flat plate. In this embodiment, the material of the first member ME1 and the second member ME2 is a carbon fiber composite material.

[0013] The shape of the fillet forming die 10 is manufactured to match the respective shapes of the first member ME1 and the second member ME2. As shown in FIG. 1, in this embodiment, the corner formed by the first member ME1 and the second member ME2 extends linearly. Therefore, the fillet forming die 10 of this embodiment has a shape that extends in an axial direction parallel to the direction in which this corner extends. In addition, the shape of the fillet forming surface 11 is an arc when viewed from the side along the axial direction of the fillet forming die 10, which is the direction in which this corner extends.

[0014] As shown in "S10" in FIG. 2, in step S10, the two fillet forming dies 10 are arranged so that the fillet forming surfaces 11 of each are in contact with the first member ME1 at desired positions. Here, the desired positions are positions where the distance D1 between the bonding surface ME1a of the first member ME1, on which the adhesive GL is arranged, and the second member ME2 is a desired distance, and where each fillet forming surface 11 is in contact with the first member ME1, as shown in "S14" in FIG. 2. The distance D1 is the thickness of the adhesive GL when the first member ME1 and the second member ME2 are bonded together. In step S10, the two fillet forming dies 10 are positioned so that the distance between the bonding surface ME1a and an imaginary plane PL, which includes the opposing surfaces 12 of the two fillet forming dies 10, is a desired distance. A specific method of positioning is to place a first flat plate (not shown) having the desired thickness on the adhesive surface ME1a, stack a second flat plate (not shown) on the first flat plate, and position the fillet forming mold 10 so that the second flat plate and the opposing surface 12 are in contact with each other.

[0015] In step S10, after the two fillet forming dies 10 are positioned, the two fillet forming dies 10 are temporarily fixed to the first member ME1. As a method of temporary fixing, a method using double-sided tape or a fastening member can be used. As a specific method, a method can be used in which the fillet forming die 10 is provided with a temporary fixing portion for temporary fixing (not shown), and double-sided tape or a fastening member is attached to the temporary fixing portion for fixing. In step S10, after temporary fixing, an adhesive GL is applied to the adhesive surface ME1a. The adhesive GL is applied linearly along a direction parallel to the axial direction of the fillet forming die 10. The adhesive GL may be applied manually by an operator or by a robot.

[0016] The method of temporary fixing is not limited to the above, and for example, the fillet forming die 10, the first member ME1, and the second member ME2 may be temporarily fixed using a fixing jig that is separate from them.

[0017] In this embodiment, a so-called two-component epoxy resin is used as the adhesive GL. Specifically, the adhesive GL is formed by mixing a first liquid and a second liquid whose main components are different epoxy resins, and is applied to the adhesive surface ME1a.

[0018] As shown in "S12" in FIG. 2, in step S12, the second member ME2 is positioned so as to face the opposing surfaces 12 of the two fillet forming dies 10. The second member ME2 is moved downward until it abuts against the opposing surfaces 12. As the second member ME2 is moved downward, the adhesive GL spreads to fill the space surrounded by the first member ME1, the two fillet forming dies 10, and the second member ME2. In other words, the adhesive GL is formed into a shape that conforms to the fillet forming surfaces 11. The amount of adhesive GL placed on the bonding surface ME1a is set to be sufficient to fill the space. The fillet forming die 10 is positioned so that the fillet forming surface 11 is in contact with the first member ME1. This prevents the adhesive GL from dripping from the contact area between the fillet forming surface 11 and the first member ME1. This reduces the amount of work required to clean up the dripping adhesive GL. In this embodiment, it is assumed that excess adhesive GL drips from the axial end of the fillet forming die 10. Therefore, it is preferable to place a container below the axial end of the fillet forming die 10 to receive the excess adhesive GL.

[0019] In step S12, instead of moving the second member ME2 downward, the first member ME1 may be moved upward so as to approach the second member ME2 whose position in the Z direction is fixed.

[0020] 2, the adhesive GL hardens while the second member ME2 is in contact with the opposing surface 12. In this embodiment, as described above, a two-component epoxy resin is used, and therefore the adhesive GL hardens by a chemical reaction.

[0021] After the adhesive GL has hardened and bonded the first member ME1 and the second member ME2, the two fillet forming dies 10 are separated from the first member ME1 and the second member ME2 in "S16" of FIG. 2. Specifically, the two fillet forming dies 10 are removed from the first member ME1. As described above, the adhesive GL is formed along the fillet forming surface 11. Therefore, a fillet FI is formed in the hardened adhesive GL. The fillet FI formed in this manner has a uniform shape because it is formed using the fillet forming dies 10.

[0022] The timing at which the two fillet forming dies 10 are removed from the first member ME1 does not necessarily have to be when the adhesive GL has completely hardened. For example, the fillet forming dies 10 may be removed when the deep part of the adhesive GL is still unhardened and the surface of the adhesive GL has hardened to such an extent that the shape of the fillet FI can be maintained.

[0023] A commonly used bonding method involves scraping off excess adhesive GL from the corners formed between the first member ME1 and the second member ME2 with a spatula. However, when this method is adopted, depending on the viscosity of the adhesive GL, the adhesive GL may drip due to gravity or the fillet FI may be deformed. In this regard, according to the present embodiment, the fillet forming surface 11 is disposed in contact with the first member ME1, thereby preventing the adhesive GL from dripping from the contact area between the fillet forming surface 11 and the first member ME1. Furthermore, according to this embodiment, the fillet FI is formed by the fillet forming surface 11, so a fillet FI with a desired shape can be formed regardless of the properties of the adhesive GL, such as the surface tension and viscosity. Furthermore, when using the above-mentioned commonly used bonding method, depending on the shapes of the first member ME1 and the second member ME2, the space may be limited, making it difficult to reach the bonded portion between the first member ME1 and the second member ME2. In this regard, according to this embodiment, even if there is not enough space to reach the bonded portion, as long as there is enough space to insert the fillet forming mold 10, the fillet FI can be formed.

[0024] According to the first embodiment described above, the fillet forming die 10 includes a fillet forming surface 11. The fillet forming surface 11 has a curved surface that forms a fillet FI of the adhesive GL at a corner formed by the first member ME1 and the second member ME2 that are bonded to each other. By using the fillet forming die 10, the fillet FI is formed in the adhesive GL by the fillet forming surface 11, thereby reducing variation in the shape of the fillet FI formed in the adhesive GL. This reduces stress concentration in the bonded portion between the first member ME1 and the second member ME2, thereby improving the bond strength between the first member ME1 and the second member ME2. Furthermore, because the fillet forming surface 11 abuts against the first member ME1, dripping of the adhesive GL from the contact portion between the fillet forming surface 11 and the first member ME1 is suppressed.

[0025] Furthermore, when the fillet forming die 10 is viewed from the side along the direction of the angle formed by the first member ME1 and the second member ME2, the shape of the fillet forming surface 11 is an arc. This allows the cross-sectional shape of the fillet FI to be an arc, further improving the adhesive strength between the first member ME1 and the second member ME2.

[0026] The bonding process includes step S10 as a first process, steps S12 and S14 as second processes, and step S16 as a third process. In step S14, the fillet forming die 10 and the second member ME2 are placed relative to the first member ME1 on which the adhesive GL is placed, so that the fillet forming surface 11 abuts against the first member ME1 and the opposing surface 12 abuts against the second member ME2. According to this bonding process, the fillet FI is formed by the fillet forming die 10, which reduces variation in the shape of the fillet FI formed in the adhesive GL.

[0027] In the bonding process, in step S12, the fillet forming die 10 is temporarily fixed so that the fillet forming surface 11 abuts against the first member ME1. Thereafter, in step S14, the second member ME2 is brought closer to the first member ME1 on which the adhesive GL is applied until the second member ME2 abuts against the opposing surface 12. In this way, by temporarily fixing the fillet forming die 10 in step S12, it is possible to improve the positional accuracy of the second member ME2 relative to the first member ME1.

[0028] B. Second embodiment: FIG. 3 is a diagram illustrating the bonding process of the second embodiment. The same components as those in the first embodiment are assigned the same reference numerals, and only the differences will be described. In step S10 of the bonding process of the first embodiment, the two fillet forming dies 10 are temporarily fixed to the first member ME1. In contrast, in this embodiment, as shown in FIG. 3, the two fillet forming dies 10 are temporarily fixed to the second member ME2. In this embodiment, the two fillet forming dies 10 are positioned relative to the second member ME2 so that the distance between the two fillet forming surfaces 11 of the two fillet forming dies 10 is equal to the width of the first member ME1 in the X direction.

[0029] After the two fillet forming dies 10 are temporarily fixed to the second member ME2, an adhesive GL is applied to the bonding surface ME1a of the first member ME1, and then the second member ME2 is moved so that the second member ME2 approaches the first member ME1 until the first member ME1 abuts against the fillet forming surface 11.

[0030] According to the second embodiment described above, the first member ME1 can be easily positioned relative to the second member ME2 in the surface direction of the second member ME2.

[0031] C. Third embodiment: 4 is a diagram illustrating a fillet forming die 110 of the third embodiment. The same components as those in the first embodiment are given the same reference numerals, and detailed descriptions thereof will be omitted as appropriate. In the bonding step of this embodiment, three fillet forming dies 10 having the same structure as the fillet forming die 10 of the first embodiment are used, and one fillet forming die 110 having a different structure from the fillet forming die 10 of the first embodiment is used.

[0032] The fillet forming die 110 differs from the fillet forming die 10 of the first embodiment in that it has a groove 13. The groove 13 extends from a first side SI1 to a second side SI2 of the opposing surface 12. In this embodiment, the groove 13 is formed in the opposing surface 12 at approximately the center in the axial direction of the fillet forming die 110. The groove 13 is formed in the opposing surface 12 along the width direction of the opposing surface 12, which is perpendicular to the axial direction of the fillet forming die 110.

[0033] The shape of the groove 13 is not limited to the shape shown in FIG. 4. For example, a plurality of grooves 13 may be formed on the opposing surface 12. The direction in which the groove 13 extends is not limited to the width direction perpendicular to the axial direction of the fillet forming die 110, but may be inclined relative to the width direction. The bottom surface of the groove 13 may be inclined so that the position of the bottom on the second side SI2 is located lower than the position of the bottom on the first side SI1. According to this shape, when excess adhesive GL flows through the groove 13, it is possible to make the adhesive GL flow more easily toward the second side SI2, as will be described later.

[0034] In the bonding step of this embodiment, three fillet forming dies 10 and one fillet forming die 110 are arranged to surround the first member ME1. The arrangement is the same as in the first embodiment, and the three fillet forming dies 10 and one fillet forming die 110 are arranged so that their respective fillet forming surfaces 11 abut against the first member ME1. In this embodiment, the first member ME1 is rectangular in a plan view seen along the Z direction. Therefore, the three fillet forming dies 10 and one fillet forming die 110 are arranged so that their respective fillet forming surfaces 11 form a rectangle in a plan view.

[0035] Subsequent steps are also performed in the same manner as in the first embodiment. That is, after the three fillet forming dies 10 and one fillet forming die 110 are temporarily fixed to the first member ME1, adhesive GL is applied to the bonding surface ME1a. Thereafter, when the second member ME2 is brought closer until it abuts against the opposing surface 12, excess adhesive GL flows into the groove 13. The excess adhesive GL that has flowed into the groove 13 flows along the groove 13 toward the second side SI2 and drips downward from the second side SI2 as indicated by the dashed arrow. For this reason, it is preferable to place a container below the groove 13 to collect the dripping adhesive GL.

[0036] According to the third embodiment described above, in the bonding step, three fillet forming dies 10 and one fillet forming die 110 are arranged to surround the first member ME1. Therefore, fillets FI can be formed in the adhesive GL that bonds the first member ME1 and the second member ME2 over the entire periphery in a plan view. Furthermore, because the fillet forming die 110 has grooves 13, excess adhesive GL flows into the grooves 13. This further reduces the possibility that excess adhesive GL will adhere to the first member ME1 or the second member ME2.

[0037] D. Other Embodiments: (D1) In the bonding step of the first embodiment, two fillet forming dies 10 are used. The number of fillet forming dies 10 used in the bonding step is not limited to two, and may be one. By using at least one fillet forming die 10, a fillet FI can be formed in a portion of the bonding portion between the first member ME1 and the second member ME2.

[0038] (D2) The fillet forming die 10 of the first embodiment described above includes a fillet forming surface 11 and an opposing surface 12. In another embodiment, the fillet forming die 10 may include the fillet forming surface 11 but not the opposing surface 12. In this embodiment, the fillet forming die 10 is positioned so that the fillet forming surface 11 abuts against each of the first member ME1 and the second member ME2, thereby forming a fillet FI in the adhesive GL. Note that a configuration in which the fillet forming die 10 includes the opposing surface 12, as in the first embodiment, is preferable because the second member ME2 can be stably positioned by abutting the opposing surface 12 against the opposing surface 12. For the same reason, although the opposing surface 12 is connected to one of the two ends of the fillet forming surface 11 in the first embodiment, the opposing surface 12 may be provided at both ends of the fillet forming surface 11.

[0039] (D3) The fillet forming die 10 of the first embodiment has a cylindrical shape. The shape of the fillet forming die 10 is not limited to a cylindrical shape, and may be a solid pillar shape or a plate shape having a fillet forming surface 11 and an opposing surface 12.

[0040] (D4) In the first embodiment, the shape of the curved surface of the fillet forming surface 11 in a side view is an arc, but this is not limited thereto. For example, the shape of the fillet forming surface 11 in a side view may be a shape in which multiple curves with different curvatures are connected. Furthermore, in the above embodiment, the entire fillet forming surface 11 is a curved surface that forms a fillet FI of adhesive GL at the corner formed by the first member ME1 and the second member ME2. In another embodiment, only a portion of the fillet forming surface 11 may be a curved surface that forms a fillet FI of adhesive GL at the corner formed by the first member ME1 and the second member ME2. For example, the fillet forming surface 11 may be configured by combining a curved surface and a flat surface.

[0041] (D5) In the first embodiment described above, the first member ME1 is an L-shaped member, and the second member ME2 is a flat plate. The shapes of the first member ME1 and the second member ME2 are not limited to this. For example, the fillet forming die 10 can be used in a configuration in which the first member ME1 and the second member ME2 are each a flat plate, and the second member ME2 is placed on top of the first member ME1. Furthermore, the fillet forming die 10 can be used in a configuration in which the first member ME1 is a cylinder, the second member ME2 is a flat plate, and the second member ME2 is placed at the end of the first member ME1. The shape of the fillet forming die 10 is not limited to a shape extending in the axial direction. For example, if the first member ME1 is a cylinder, the fillet forming die 10 may have an annular shape that matches the shape of the first member ME1.

[0042] (D6) In the first embodiment, the material of the first member ME1 and the second member ME2 is a carbon fiber composite material, and the adhesive GL is a two-component epoxy resin. The materials of the first member ME1 and the second member ME2 and the material of the adhesive GL are not limited to these. For example, the material of the first member ME1 and the second member ME2 may be a metal material, a resin material, or wood. Furthermore, the material of the adhesive GL may be a silicone resin, a phenolic resin, a thermoplastic resin, or a thermosetting resin.

[0043] The present disclosure is not limited to the above-described embodiments and can be realized in various configurations without departing from the spirit thereof. For example, the technical features of the embodiments corresponding to the technical features in each aspect described in the Summary of the Invention section can be appropriately replaced or combined to solve some or all of the above-described problems or achieve some or all of the above-described effects. Furthermore, if a technical feature is not described as essential in this specification, it can be appropriately deleted. [Explanation of symbols]

[0044] 10, 110...Fillet forming mold, 11...Fillet forming surface, 12...Opposite surface, 13...Groove, FI...Fillet, GL...Adhesive, ME1...First member, ME2...Second member, SI1...First side, SI2...Second side

Claims

1. A fillet forming mold, a fillet forming surface disposed in contact with the first member; The fillet forming surface has a curved surface that forms a fillet of the adhesive at a corner formed by the first member and a second member that is bonded to the first member with an adhesive.

2. The fillet forming die according to claim 1, an opposing surface connected to the fillet forming surface and abutting against the second member; the fillet forming die has a shape extending in the direction in which the corner extends, The fillet forming die has a shape of a circular arc in a side view of the fillet forming die seen along the direction in which the corner extends.

3. The fillet forming die according to claim 2, The opposing surface has a first side connected to the fillet forming surface, a second side opposite to the first side, and a groove extending from the first side to the second side.

4. A bonding method for bonding a first member and a second member using a fillet forming die, comprising: the fillet forming die includes a fillet forming surface and an opposing surface connected to the fillet forming surface, The bonding method comprises: a first step of placing an adhesive on the first member; a second step of placing the fillet forming die and the second member relative to the first member on which the adhesive is applied so that the fillet forming surface abuts against the first member and the opposing surface abuts against the second member; and a third step of separating the fillet forming die from the first member and the second member after the adhesive has hardened to bond the first member and the second member.

5. The bonding method according to claim 4, In the second step, the fillet forming mold is temporarily fixed so that the fillet forming surface abuts the first member, and then the second member is brought closer to the first member on which the adhesive is applied until the second member abuts the opposing surface.

Images